A multi-particle crushing apparatus for studying rock fragmentation due to repeated impacts

Rock crushing is a common process in mining and related operations. Although a number of particle crushing tests have been proposed in the literature, most of them are concerned with single-particle crushing, i.e., a single rock sample is crushed in each test. Considering the realistic scenario in crushers where many fragments are involved, a laboratory crushing apparatus is developed in this study. This device consists of a Hopkinson pressure bar system and a piston-holder system. The Hopkinson pressure bar system is used to apply calibrated dynamic loads to the piston-holder system, and the piston-holder system is used to hold rock samples and to recover fragments for subsequent particle size analysis. The rock samples are subjected to three to seven impacts under three impact velocities (2.2, 3.8, and 5.0 m/s), with the feed size of the rock particle samples limited between 9.5 and 12.7 mm. Several key parameters are determined from this test, including particle size distribution parameters, impact velocity, loading pressure, and total work. The results show that the total work correlates well with resulting fragmentation size distribution, and the apparatus provides a useful tool for studying the mechanism of crushing, which further provides guidelines for the design of commercial crushers.